Download Torque-Hub Planetary Final Drive CW18 Series Service Manual

Torque-Hub® Planetary Final Drive
CW18 Series Service Manual
Rev 01/22/13
1
While every precaution has been taken in the preparation of this document, Fairfield Manufacturing Co. Inc. assumes no
liability with respect to the use of the documentation described herein, or for any act or omission of Fairfield Manufacturing
Co. Inc. concerning this documentation. Torque-Hub® is a registered trademark of Fairfield Manufacturing Co. Inc.
Features and specifications are subject to change without notice.
2
Planetary Final Drive Service Manual
Content
Disassembly Instructions
Assembly Instructions
General Information
Introduction
Brake Test
Roll and Leak Test
Tightening and Torquing Bolts
Lubrication Information
Seal Installation Instructions
Main Disassembly
Cover Disassembly
Input Coupling Disassembly
Input Brake Disassembly
Housing-Spindle Disassembly
Output Planet Gear Disassembly
Input Carrier Disassembly
Cover Subassembly
Input Carrier Subassembly
Output Planet Gear Subassembly
Input Coupling Subassembly
Housing-Spindle Subassembly
Main Assembly
Assembly Drawing
Parts List
Assembly Tools
Contact Information
4
5
8
11
12
14
18
22
24
26
28
32
33
36
38
40
41
43
46
51
52
54
70
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Planetary Final Drive Service Manual
Introduction
This manual is a step-by-step guide to the disassembly and
®
assembly of the CW18 Torque-Hub units with ratios of 51:1 or
lower. It is designed for the customer or mechanic who is repairing
®
this particular Torque-Hub model.
Users of this manual should note that each part mentioned is
followed by an identification number enclosed in parentheses.
These part numbers may be referred to in the Parts List and
Assembly Drawing sections of this manual.
Specialized tools used to assemble this unit are noted in the
assembly procedures and diagrammed in the Assembly Tools
section.
Users should familiarize themselves with the procedures for roll and
leak testing, as well as bolt tightening and torquing found on the
following three pages before starting any repairs.
Standard safety practices should be followed during the
disassembly and assembly procedures described. Safety glasses
and safety shoes should be worn, and heavy, heat resistant gloves
should be used when handling heated components. Be especially
alert when you see the word CAUTION. This indicates that a
particular operation could cause personal injury if not performed
properly or if certain safety procedures are not followed. The word
NOTE is used to bring attention to certain procedures or helpful
hints that will aid in the disassembly and assembly process.
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Planetary Final Drive Service Manual
Brake Test
The Brake Test
To perform a brake check, use a M12x1.5 metric fitting. Install a
hydraulic hand pump with pressure gauge into brake port in spindle
(1A) using metric thread fitting.
Place ROLL TEST Tool (refer to table on page 8) into input
coupling.
Apply 25 in-lbs torque. While trying to rotate tool, pump the handle
on the hydraulic hand pump and increase the pressure until the
brake releases. The brake is released when you are able to rotate
the tool.
Record the release pressure. If the brake does not release within
limits shown in the brake chart on page 6, check to see if it has the
proper number of springs using the SPRING CHECKING
PROCEDURE. Increase to maximum pressure (refer to brake chart
on page 6) and hold at that pressure for one minute. If the brake
does not leak or lose pressure, the unit has passed the brake test. If
the brake loses pressure, attempt to repair the leak using the leak
repair procedure at end of this procedure.
While brake is still released, roll check the unit for one revolution of
the output member by rotating the tool. Bleed off pressure slowly
while rotating the ROLL TEST Tool.
Record the pressure at which the brake locks up. Using a clean rag,
wipe off excess fluid from around the brake port and install the pipe
plug.
Continued on Next Page
5
BRAKE CHART
th
9 DIGIT
IN
MODEL
CODE
(INPUT
BRAKE)
1
BRAKE
PART
NUMBER
NUMBER
OF
SPRINGS
RELEASE
PRESSURE
MIN (psi)
RELEASE
PRESSURE
MAX (psi)
FULL
RELEASE
PRESSURE
(psi)
MAXIMUM
PRESSURE
(psi)
BRAKE
TORQUE
(in-lbs)
AM902446A
11
100
138
145
3000
3754
2
AM902446B
16
144
182
210
3000
5411
3
AM902446C
19
170
214
250
3000
6386
4
AM902446G
13
118
149
171
3000
4422
J
AM902446A
11
102
129
145
3000
3110
K
AM902446B
16
147
184
210
3000
4481
L
AM902446C
19
174
217
250
3000
5288
M
AM902446G
13
120
151
171
3000
3662
A
902315A
6
92
123
130
3000
2940
B
902315B
9
138
184
190
3000
4410
C
902315
11
168
225
230
3000
5390
G
902315C
7
107
143
150
3000
3430
SPRING CHECKING PROCEDURE:
Install input brake bolts into holes in the brake piston. Tighten bolts
in such a way to ensure the brake piston remains straight while
being compressed into the brake cavity of the spindle.
Carefully remove the retaining ring from the spindle. Slowly remove
bolts from the input brake. Remove the cover plate from the end of
the input brake and count the number of springs in brake. If number
of springs matches the number in the BRAKE CHART, go to the
next step. If the number of springs does not match the number in
the BRAKE CHART above, install the correct number of springs.
Continued on Next Page
6
Install the Brake Cover Plate using input brake bolts. Tighten
screws in such a way that to ensure the Brake Cover Plate remains
straight while being compressed into the brake cavity of the spindle.
Install the large retaining ring into the groove in spindle (1A),
making sure it is seated properly. Remove all remaining screws
from the brake piston and discard.
NOTE: USE CAUTION WHEN REMOVING SCREWS AS THEY
ARE SUBJECT TO SPRING PRESSURE. MAKE SURE THE
RETAINING RING IS SECURED BEFORE REMOVING BOLTS.
Re-test the input brake. If release and/or lockup pressures still do
not match the brake chart, contact the Oerlikon Fairfield service
department.
BRAKE LEAK REPAIR PROCEDURE:
Install input brake bolts into holes in the Brake Piston. Tighten
screws in such a way to ensure the Brake Cover Plate remains
straight while being compressed into brake cavity of Spindle.
Carefully remove the Retaining Ring from the Spindle. Using two
eyebolts threaded into opposite holes in the Brake Piston, remove
the Brake Piston from the Spindle.
Check O-rings, Backup Rings, and brake cavity in Spindle for
damage. If no damage is found, reinstall the Input Brake according
to the Input Brake Installation Procedure in the assembly
instructions chapter and perform pressure test again. If brake still
leaks, contact the Oerlikon Fairfield service department.
Reference: Sample Model CW18_ _ _ _ X _ _ _ _. The ‘X’ is the
brake option (Model Code). Consult Oerlikon Fairfield for other
brake options.
NOTE: Failure to perform this test may result in damaged or
ineffective brake parts.
7
Planetary Final Drive Service Manual
Roll and Leak Test
®
Torque-Hub units should always be roll and leak tested before
disassembly (if possible) and after assembly to make sure the unit’s
gears, bearings and seals are working properly. The following
information briefly outlines what to look for when performing these
tests.
The Roll Test
The purpose of the roll test is to determine if the unit’s gears are
rotating consistently, easily and properly. It should be able to rotate
the gears in the unit applying constant force to the roll checker. If
more drag is felt in the gears only at certain points, then the gears
are not rolling consistently and easily and should be examined for
improper installation or defects. Some gear packages roll with more
difficulty than others. Do not be concerned if the gears in the unit
seem to roll hard as long as they roll with consistency. Rotate the
gearbox both clockwise and counterclockwise the same number of
turns as the ratio of the unit. The gearbox ratio is the same number
as the last three numbers on the ID tag.
Model Code
Roll Test Tool
CW18Ax1xxx
T184729
CW18Dx1xxx
T184729
CW18Dx2xxx
T180149
CW18Dx4xxx
T180149
CW18Dx8xxx
T180149
8
The Leak Test
Model Code
Roll Test Tool
CW18Ex1xxx
T184729
CW18Ex2xxx
T180149
CW18Ex4xxx
T180149
CW18Ex7xxx
T201476
CW18Ex8xxx
T205279
The purpose of a leak test is to make sure the unit is airtight.
To perform a leak test, use the leak test fixture from the table on
page 10. If the tool is not available, the gearbox must be sealed to
perform the test. This can be accomplished by assembling the
sealed input device onto the gearbox at the input end and replace
one of the oil plugs with an air chuck. DO NOT EXCEED 10 PSI
PRESSURE DURING THE LEAK TEST. Higher pressure will create
a false sealing effect in assemblies with lip-seals. The unit has a
leak if the pressure gauge reading on your leak check fitting starts
to fall after the gearbox has been pressurized and allowed to
equalize. Leaks will most likely occur at the pipe plugs, the main
seal or wherever o-rings or gaskets are located. The exact location
of a leak can usually be detected by brushing a soap and water
solution around the main seal and where the o-rings or gaskets
meet on the exterior of the unit and then checking for air bubbles. If
a leak is detected in a seal, o-ring or gasket, the part must be
replaced and the unit rechecked. Leak test at 10 psi for 20 minutes.
Continued on Next Page
9
Model Code
Leak Test Tool
CW18A11xxAxxx
T182969
CW18A11xxZxxx
T188489
CW18D11xxAxxx
T188489
CW18D12xx4xxx
T181663
CW18D14xxBxxx
T184035
CW18D18xx4xxx
T198122
CW18D21xxAxxx
T188489
CW18E11xxAxxx
T188489
CW18E11xx4xxx
T188489
CW18E12xx4xxx
T181663
CW18E14xxBxxx
T184035
CW18E17xx8xxx
T163056
CW18E18xx4xxx
T198122
CW18E54xxBxxx
T184035
10
Planetary Final Drive Service Manual
Tightening and Torquing Bolts
If an air impact wrench is used to tighten bolts, extreme care should
be taken to ensure the bolts are not tightened beyond their specified
torque. The following steps describe how to tighten and torque bolts
or socket head cap screws in a bolt circle.
1. Tighten (but do not torque) bolt “A” until snug.
2. Go to the opposite side of the bolt circle and tighten bolt “B” until
equally snug.
3. Crisscross around the bolt circle and tighten the remaining bolts.
4. Use a torque wrench to apply the specified torque to bolt “A.”
5. Using the same sequence, crisscross around the bolt circle and
apply an equal torque to the remaining bolts.
11
Planetary Final Drive Service Manual
Lubrication Information
®
General Properties
The lubricant used in most Torque-Hub drives should be
petroleum-based gear fluid containing anti-oxidation, anti-foaming
and extreme pressure additives. The lubricant should have a
minimum viscosity index of 95 cst and maintain a minimum viscosity
of 40 cst under normal operating conditions. Some applications
require special considerations; consult the machine manufacturer
and Oerlikon Fairfield for more additional information.
The table below lists the recommended viscosities for various
ambient operating temperatures. These recommendations are
based on temperature rise of 50° to 100°F at normal operating
conditions.
Differential Planetary
Simple Planetary
ISO Index
AGMA
Lubricant
Number
ISO Index
AGMA
Lubricant
Number
VG100
3EP
VG100
3EP
-5°to 40° F
VG150
4EP
VG100
3EP
40° to105° F
VG220/VG320
5EP/6EP
VG150/VG220
4EP/5EP
VG460
7EP
VG320
6EP
Ambient
Temperature
-40° to -5° F
(1)
105° to 150° F
(2)
Footnotes
1.
For operation in this ambient temperature range, synthetic oil is recommended with a pour point of
10°F lower than the minimum ambient temperature.
2. For operation in this ambient temperature range, synthetic oil is recommended for proper lubricant
life at elevated temperatures.
Continued on Next Page
12
Maintenance
®
Oil amounts for each series of Torque-Hub drives are indicated in
the appropriate series literature. An initial oil change should be
made after the first 50 hours of operation. Subsequent oil changes
should be made at 1,000 hour intervals or annually, whichever
comes first.
Oil temperatures should be not higher than 160° to 180°F for
continuous operation, and no higher than 200°F for intermittent
operation. For special applications, high horsepower, high speeds
or wide temperature changes, please consult Oerlikon Fairfield.
Oil Fill Level
®
When the Torque-Hub unit is mounted horizontally, unless
otherwise specified, the gearbox should be filled half-full of oil.
Consult the appropriate series literature for approximate fill
®
volumes. Vertically mounted Torque-Hub units may require special
lubrication procedures. Please contact Oerlikon Fairfield for
vertically mounted applications.
13
Planetary Final Drive Service Manual
Seal Installation
The seal installation tool can be purchased from MORCOR LTD at
[email protected] part number MGT045.
To begin the procedure, all of the sealing components; Seal Rings
(metal rings); O-Rings and the housings must be clean and free of
Oil, Grease, Dirt or Dust. Always check to make sure that there are
no nicks or burrs in the housing area that could damage the Load
Ring during installation. The use of DENATURED ALCOHOL (also
known as Wood Alcohol or Shellac Thinner) and a lint free cloth is
recommended for cleaning all of these areas. NOTE: Follow all
Material Safety Data Sheet guidelines.
After all components have been wiped clean and have dried, the ORings should be placed back on the Seal Rings in their proper
position. The O-Rings must be seated completely and tightly on the
Seal Ring. Always make sure that the O-rings are not twisted or
distorted by inspecting the mold flash (seam) on the outside
diameter to see that is running “true” with the circumference.
Eliminate O-Ring twist by gently pulling a section of the O Ring (2)
rapidly away from the Seal Ring (1) and letting it “snap” back.
Warning: Do not place the Seal Rings face down on any hard or
abrasive surface to accomplish this! Once the O-Rings are back on
the Seal Rings, quickly swab out the housing with a clean lint free
cloth generously soaked it with Denatured Alcohol. This is to
temporarily lubricate the bore. Then, with the same cloth, quickly
swab the outside (O- Ring area) of the seal half to temporarily
lubricate the O-Ring.
Continued on Next Page
14
With all surfaces of the O Ring (2) wet with alcohol use the
Installation Tool (9) to position the Seal Ring (1) and the O-Ring (2)
squarely against the Housing (5) as shown. Use sudden and even
pressure to pop (push) the Toric Ring under the Retaining Lip (3) of
the housing.
NOTE: It is important for the O-ring as well as the housing bore to
be wet with Alcohol during this process. Visually inspect the
positioning of the O-Ring and Seal Ring relative to each other, as
well as relative to the housing. Always make sure that everything is
seated symmetrically. NOTE: Misaligned seals and improperly
seated O-Rings can cause leakage or premature failure.
If small adjustments are necessary; do not push directly on the Seal
Ring (1) use the Installation tool (9) to push down or use the
Adjustment Tool (11) to pull up. NOTE: Never use sharp
instruments such as screwdrivers. They can cause permanent
damage to the O-Ring and/or Seal Ring, which may lead to rapid
failure. For twists or obvious bulges in the O-Ring or if the Seal Ring
is "riding up" on the O-Ring and cannot be adjusted, always remove
the seal half and repeat the procedure, beginning with the cleaning
process.
Continued on Next Page
15
After a successful installation always wait a few minutes for the
Alcohol to completely evaporate, before assembling. The Alcohol is
necessary as a lubricant during the installation process, but for
assembly the area must be clean and dry in order for the O- Ring to
properly "crush" into its final position. After the two seal halves have
been installed in their respective housings and just prior to
assembly, the faces should be thoroughly cleaned with Denatured
Alcohol. Next, apply a thin film of oil (EP90 the same oil that will be
used to fill the assembly) to the faces of the Seal Rings with a clean
lint free cloth. Warning: Be careful not to get oil on the O- Rings!
The seal set is now ready to be drawn together in the assembled
unit.
Check the assembled height (A) in a least four places spaced 90°
apart.
16
DISASSEMBLY
17
Planetary Final Drive Service Manual
Main Disassembly
Continued on Next Page
18
1.
Perform a roll check and a leak check prior to disassembling the unit.
2.
Remove the three magnetic Pipe Plugs (1U/14) and drain the oil out of the gearbox.
NOTE: Record the condition and volume of the oil.
3.
Remove Bolts (27/13) from the Cover Subassembly.
4.
Lift the Cover Subassembly off of the unit.
Continued on Next Page
19
5.
Remove the Input Shaft (7) if applicable.
6.
Lift out the Input Carrier Subassembly from Hub-Spindle Subassembly.
7.
Remove the Second Stage Sun Gear (12).
8.
Lift the Ring Gear (4/6) off of the Housing Spindle Subassembly.
9.
Remove the O-ring (5) from between the Housing (1G) and the Ring Gear (4/6).
CAUTION: Safety glasses must be worn during these next steps.
10.
Remove the four External Retaining Rings (3C) that are holding the spindle Planet Gears
(3A) in place.
11.
Carefully pry the Planet Gears (3A) off of the spindle posts. Be careful to not damage the
Thrust Spacer (2).
12.
Remove Thrust Spacer (2) from Housing Spindle Subassembly.
NOTE: Skip steps 13, 14 and 15 if unit does not have Adaptor Mount (24).
Continued on Next Page
20
13.
Remove Adaptor Mount (24) from Housing Spindle Subassembly by uninstalling Bolts (26).
NOTE: Skip step 14, if Thrust Washer (30) is glued onto Adaptor Mount (24)
14.
Remove Thrust Washer (30) from Adaptor Mount (24).
15.
Remove O-Ring (25) from groove in Adaptor Mount (24) and discard O-Ring.
16.
Remove the Input Brake Subassembly out of Hub-Spindle Subassembly (Refer page 26 for
Input Brake Disassembly).
17.
Remove the Input Coupling Subassembly (9) out of Hub-Spindle Subassembly.
This concludes the Main Disassembly.
21
Planetary Final Drive Service Manual
Cover Disassembly
Continued on Next Page
22
1.
Remove the O-Ring (5) from groove in the Cover (6A/12) and discard O-Ring.
NOTE: Skip step below if the unit has Thrust Washers glued in place.
2.
Remove Thrust Washers (10) and (11) from pockets in the Cover (6A/12).
This concludes the Cover Disassembly.
23
Planetary Final Drive Service Manual
Input Coupling Disassembly
Continued on Next Page
24
CAUTION: Safety glasses must be worn during these next step.
1.
Remove Retaining Ring (22/18C) from bore of Coupling (9/18A).
NOTE: Skip step 2 for Assembly with Adaptor Mount.
2.
Remove Retaining Ring (18B) from retaining ring groove of Coupling (9/18A).
This concludes the Input Coupling Disassembly.
25
Planetary Final Drive Service Manual
Input Brake Disassembly
Continued on Next Page
26
1.
Remove Input Coupling Subassembly from the unit.
2.
Place Spindle (1A) such that the flange side is up.
CAUTION: Safety glasses must be worn during these next steps.
3.
Install the Input Brake Bolts through the Thrust Plate (18B) and into the Brake Piston (18A)
and tighten incrementally to compress the brake springs (18R) and take pressure off of the
Retaining Ring (18E).
4.
Remove the Retaining Ring (18E) from counter bore of the Spindle (1A).
5.
Remove the Input Brake Bolts from the Brake Piston (18A) incrementally to release the
tension off the springs slowly.
6.
Remove the Brake Thrust Plate (18B).
7.
Remove the Brake Springs (18R) from the Brake Piston (18A).
8.
Remove the Brake Piston (18A) out of the Spindle (1A).
9.
Remove the Backup Ring (18H) and the O-ring (18F) from grooves in the Spindle (1A).
10.
Remove the Backup Ring (18I) and the O-ring (18G) from grooves in the Spindle (1A).
11.
Remove the Stators (18D) and Rotors (18C) from the spindle counter bore.
12.
Remove Plastic Plug (21) from Spindle (1A) if applicable.
13.
Remove Spacer (18J) from the spindle (1A), applicable for Splined Brake Assembly only.
This concludes the Input Brake Disassembly.
27
Planetary Final Drive Service Manual
Housing-Spindle Disassembly
Continued on Next Page
28
1.
Set the unit on a bench so that the Spindle (1A) flange is down.
Continued on Next Page
29
2.
Using a small drill bit (typically 1/8”), drill from the top of the bearing nut to the bottom as
shown below.
3.
Using a larger drill bit (typically 5/16”), drill the bearing nut from the shoulder of the bearing
nut to the bottom as shown below.
4.
Using a chisel, split open the bearing nut through the larger drilled bore as shown below.
Continued on Next Page
30
5.
Remove Bearing Nut (1E) out of Hub-Spindle Subassembly.
6.
Discard Bearing Nut (1E). A new locknut must be used for reassembly.
7.
Turn the unit over and carefully place the unit on a support base until the Spindle (1A) rests
on it. Ensure there is enough gap to lower the Housing (1G) down.
8.
Use a dead blow hammer on the Housing (1G) flange to drive the inboard Bearing Cone
(1F) off of the Spindle.
9.
Lift the Spindle (1A) out of the Housing (1G).
10.
Remove the Face Seal (1B) halves or Outer of Lip Seal (1B) from the Housing (1G).
11.
Remove the Bearing Cone (1D/1F) from the Spindle (1A).
12.
Remove the Bearing Cone (1C) from the Spindle (1A).
13.
Using a hammer and punch drive the inboard Bearing Cup (1C/1E) out of the Housing (1G).
Be careful not to damage the counter bore in the housing.
14.
Turn the Housing (1G) over and drive the outboard Bearing Cup (1E) out of the Housing. Be
careful not to damage the counter-bore in the housing.
15.
Remove the other Face Seal (1B) half or the remaining inner sleeve of Lip Seal (1B) from
the Spindle (1A).
This concludes the Housing-Spindle Disassembly.
31
Planetary Final Drive Service Manual
Output Planet Gear Disassembly
1.
Place the Planet Gear Sub Assembly on bench.
CAUTION: Safety glasses must be worn during this next steps.
2.
Remove the upper Retaining Ring (3D) from groove of the Planet Gear (3A).
3.
Remover Spacer Rings from either side of the Roller Bearing Assembly (3B).
4.
Remove the Roller Bearing assembly (3B) and carefully slide into a snug fitting tube.
5.
Remove the lower Retaining Ring (3D) from groove of the Planet Gear (3A).
This concludes the Output Carrier Disassembly.
32
Planetary Final Drive Service Manual
Input Carrier Disassembly
1.
Drive the Planet Shaft (8D) out of the Carrier (8A) pin holes; forcing the Roll Pin (8E) to
sheer off.
2.
Hold on to the Planet Gear (8F) and push the Planet Shaft (8D) out of the Carrier (8A). The
Thrust Washers (8B) will slide off the shaft as it is removed.
3.
Using a hammer and punch, drive the Roll Pin (8E) out of the Planet Shaft (8D) and Carrier
(8A).
4.
Remove the Needle Bearings (8C) from the inside of the Planet Gear (8F).
5.
Repeat steps 1-4 for the remaining two Planet Gears (8F).
This concludes the Input Carrier Disassembly.
33
THIS PAGE
INTENTIONALLY
LEFT BLANK
34
ASSEMBLY
35
Planetary Final Drive Service Manual
Cover Subassembly
Continued on Next Page
36
1.
Install three Pipe Plugs (1U/14) into the Cover (6A/12).
2.
Grease the O-ring (5) and place it in the groove in the Cover (6A/12).
NOTE: Skip step below if the unit has Thrust Washers glued in place.
3.
Place the Thrust Washers (10) and (11) into counter bore of Cover (6A/12) using grease to
hold it in place.
This concludes the Cover Subassembly.
37
Planetary Final Drive Service Manual
Input Carrier Subassembly
1.
Apply a liberal coat of grease to the bore of the Planet Gear (8F). This will enable the Needle
Rollers (8C) to be held in place during assembly.
2.
Install Needle Rollers (8C) into the bore of each of the three Planet Gears (8F).
NOTE: The last roller installed must be installed end wise. That is, the end of the last roller
must be placed in between the ends of the two rollers that form the space, and then slide
parallel to the other rollers into place.
3.
Place the Carrier (8A) into the tool fixture so that one of the roll pin holes is straight up.
4.
Start Planet Shaft (8D), with end opposite roll pin hole first, through the planet shaft hole in
Carrier (8A), making sure that the roll pin hole in the planet shaft is straight up.
5.
Using ample grease to hold them in position, slide four Washers (8B) onto the Planet Shaft
(8D).
6.
Place the Planet Gear (8F) into position and push the Planet Shaft (8D) through the planet
gear without going all the way through carrier.
Continued on Next Page
38
7.
Finish pushing the Planet Shaft (8D) into the Carrier (8A) until roll pin holes of Planet Shaft
and Carrier are aligned. If necessary, align roll pin holes using a 1/8” diameter punch.
NOTE: The chamfer on the Roll Pin hole should be towards the roll pin hole in the Carrier.
8.
Drive the Roll Pin (8E) into the roll pin hole in carrier and into the Planet Shaft (8D) until the
end of the roll pin is flush with the outside diameter of Carrier (8A).
9.
Repeat steps 4 to 8 for the remaining two Planet Gears (8F).
This concludes the Input Carrier Subassembly.
39
Planetary Final Drive Service Manual
Output Planet Gear Subassembly
1.
Apply a liberal coat of grease to the bore of the Planet Gear (3A).
CAUTION: Safety glasses must be worn during this next steps.
2.
Install the upper Retaining Ring (3D) from groove of the Planet Gear (3A).
3.
Install the Roller Bearing assembly (3B) carefully.
4.
Install Spacer Rings on to the either sides of the Roller Bearing Assembly (3B).
5.
Install the lower Retaining Ring (3D) from groove of the Planet Gear (3A).
6.
Repeat steps 1 to 5 for the remaining three Planet Gears (4F).
This concludes the Output Carrier Subassembly.
40
Planetary Final Drive Service Manual
Input Coupling Subassembly
Continued on Next Page
41
CAUTION: Safety glasses must be worn during these next steps.
1.
Install the Retaining Ring (22/18C) into Coupling (9/18A).
NOTE: Skip steps 2 and 3 for Assembly with Mount Adaptor.
2.
Install the Retaining Ring (18B) from retaining ring groove of Coupling (9/18A).
This concludes the Input Coupling Subassembly.
42
Final Drive Service Manual
Housing - Spindle Subassembly
Continued on Next Page
43
1.
Using alcohol and a clean rag, wipe off bearing locations on the Housing (1G) and the
Spindle (1A).
2.
Press one Bearing Cup (1E) into bearing counter bore of spindle end of housing until seated
against shoulder in housing. Use Tool T179926/T176834.
3.
Turn Housing (1G) and press one Bearing Cup (1C/1E) using Tool T179926/T176834 into
bearing counter bore of cover end of Housing (1G) making sure that it is fully seated against
shoulder in the housing.
4.
Install two Pipe Plugs (1U) in Housing (1G).
5.
Place one Bearing Cone (1D/1F) into the Housing (1G) and, if necessary, and spray with a
light coat of oil.
NOTE: Generally seals should not be reused.
NOTE: If the unit has Face Seal, refer pages 14 through 16 for detailed instructions on
face seal installation. Then follow from Step 12.
NOTE: If the unit has two part lip seal follow steps below.
6.
Spray the housing seal bore with alcohol, then wipe with a clean rag. Ensure there is no
debris left in the bore.
7.
Using alcohol and a clean rag, wipe off seal locations on the Housing (1G) and the Spindle
(1A).
8.
Place Spindle (1A) with flange side down onto press table and apply thy 80 or alcohol to seal
diameter of Spindle (1A).
9.
Slide the inner sleeve out of the Seal assembly (1B). Insert Inner Sleeve (1B) into seal press
tool T219294. Being careful not to scratch the Seal (1B) surface. Place the seal press tool
with Seal ((1B) on to the Spindle (1A). Press seal tool with inner Sleeve (1B) on to spindle
(1A). When the Seal (1B) flange makes contact with the Spindle (1A) flange the Seal (1B) is
fully seated. With clean rag, wipe off the Seal (1B) diameter.
10.
Spray the O.D. of the outer Seal (1B) with alcohol and wipe with a clean rag. Make sure not
to touch the O.D. of the Seal (1B) after it is clean and dry. Place outer Seal (1B) into
Housing (1G) seal bore with spring side down. Align and place seal installation tool over the
Seal (1B). Press the seal into the Housing (1G) using the seal press tool T219294. When the
seal press tool makes contact with the Housing (1G) the Seal (1B) is fully seated.
11.
Carefully place Housing (1G) onto Spindle (1A) so that two halves of Lip Seal (1B) contact
each other. Do not allow Face Seal (1B) to contact bench or get damaged when flipping
Housing (1G) over. Skip to Step 21.
NOTE: Skip below steps 12 through 19, if unit has two part lip seal.
12.
Carefully place Housing (1G) onto Spindle (1A) so that two halves of Face Seal (1B) contact
each other. Do not allow Face Seal (1B) to contact bench or get damaged when flipping
Housing (1G) over.
Continued on Next Page
44
13.
Place other Bearing Cone (1C) onto Spindle (1A) until it is seated in Bearing Cup (1C) in
Housing (1G) and spray with a light coat of oil. If necessary, use Tool T176703 to press
Bearing Cone (1C) onto Spindle (1A).
14.
Install Bearing Nut (1E) onto Spindle (1A) and tighten using locknut wrench T176285.
Torque Bearing Nut (1E) to 350 ft-lbs in 100 ft-lbs increments, rotate Housing (1G) in both
directions, and then torque Bearing Nut to 350 ft-lbs. Rotate Housing (1G) in both directions
again and torque bearing nut to 350 ft-lbs. Repeat this until Bearing Nut (1E) does not move
when 350 ft-lbs of torque is applied.
LEAK CHECK THE FACE SEAL ASSEMBLY
15.
Install Cover subassembly using twenty Bolts (27).
16.
Turn unit over onto its side and plug brake port in Spindle (1A) with Pipe Plug (1U) if unit
does not have brakes.
17.
Perform LEAK TEST as per instructions on page 9.
18.
Turn unit over onto Spindle (1A) end and remove Cover subassembly.
19.
Remove Bearing Nut (1E).
20.
Apply Loctite 263 to first full threads of Spindle (1A) and full threads of Bearing Nut (1E) And
Screw Bearing Nut (1E) onto Spindle (1A) down to top of Bearing Cone. Be sure to rotate
hub as the torque is applied to properly seat the bearing. Torque the Bearing Nut (1E) to
350 ft-lbs. Rotate the Housing (1G) and recheck the Bearing Nut (1E) torque to insure that
the 350 ft-lbs is maintained. Stake the Bearing Nut (1E) in three places equally spaced, into
the spline.
This concludes the Housing-Spindle Subassembly.
45
Planetary Final Drive Service Manual
Main Assembly
Continued on Next Page
46
1.
Place Hub-Spindle Subassembly, spindle flange end down.
2.
Preheat bearing heating oven to 250°F.
3.
Install Thrust Spacer (2) into counter bore of Spindle (1A).
4.
Once oven has reached 250°F, place Planet Gear Sets (3A) into oven and leave in for 15 to
20 minutes. Do not leave gears in oven for more than 20 minutes, as metallurgical damage
can occur if gears reach 250°F. Damage can occur before gears discolor.
5.
Place Hub-Spindle Subassembly on bench.
6.
Remove Planet Gears (3A) from oven and immediately push one Planet Gear (3A), starting
with large radius on bore of Cylindrical Roller Bearing (3B), onto each planet post of Spindle
(1A) until bearing hits shoulder of planet post on Spindle (1A). If Planet Gear gets stuck on
post before bearing hits shoulder of planet post, immediately press bearing the rest of the
way on using T174699 pressing tool. Keep Planet Gears Sets (3A) together during
assembly. One set per each Spindle (1A).
NOTE: Do not beat planet gears onto spindle posts with bar stock or hammer.
CAUTION: Safety glasses must be worn during these next steps.
7.
Install Retaining Ring (3C) on each planet post of Spindle (1A).
8.
Install the O-ring (5) from between the Housing (1G) and the Ring Gear (4/6).
9.
Place Ring Gear (4/6) into Housing Spindle Subassembly with spline end of Ring Gear (4/6)
towards Cover (6) ends of Housing (1G).
10.
Install Input Carrier Subassembly into Ring Gear (4/6) with Intermediate Sun Gear (12)
facing down.
11.
If applicable, install Sun Gear (7) into input carrier planet gear mesh.
12.
Align pipe plugs (1U) to proper location per print and install Cover Subassembly (6A) onto
Housing (1G).
13.
Apply Loctite 243 to bolts (27) and install them into Housing (1G) through Ring gear (4/6)
and Cover Subassembly (6A).
Continued on Next Page
47
Continued on Next Page
48
NOTE: Use an air gun to clean up the brake port and make sure there are no chips inside.
14.
Place unit on bench such that Spindle (1A) flange side is up.
15.
Insert Coupling Sub-Assembly into Spindle (1A) bore and onto Input Shaft (7).
16.
Install Spacer (18J) into brake bore of the Hub-Spindle Assembly, applicable only for Splined
Brake assembly
17.
Starting with a Stator (18C), alternately stack and install Stators (18C) into Lobes or Splines
of Hub-Spindle and Rotors (internal splines) (18D) onto splines of Input Coupling SubAssembly (9).
18.
Stack until there are a total of 7 Stators (18C) and 6 Rotors (18D) installed.
NOTE: There should always be a stator on the top and bottom of the stack
19.
Grease and install O-Ring (18G) into Spindle O-Ring groove.
20.
Gradually feed Back-up Ring (18I) underneath O-Ring (18G). Using a small pick, push one
end of the Back-up Ring (18I) to completely seat it in the groove. This ensures that the
piston will not cut the Back-up Ring (18I) during assembly.
21.
Install large Backup Ring (18H) in groove on Piston (18A).
22.
Grease and install large O-Ring (18F) in the large-diameter groove towards the small
Diameter end of Piston (18A) on top of the large Backup Ring (18H).
23.
Press Piston (18A) into Spindle (1A) until the small end contacts the Stator (18C).
24.
Insert appropriate number of springs (18R) into piston (18A). (Refer Brake Chart in page 6).
25.
Place Pressure Plate (18B) on top of springs (18R).
CAUTION: Safety glasses must be worn during this next step.
26.
Install Input brake bolts through the Pressure Plate (18B) into Piston (18A). After springs
(18R) have been compressed enough, install Retaining Ring (18E) into Spindle (1A) groove.
Remove the Input brake bolts.
NOTE: Remove Input brake bolts from units when done, otherwise brake will not function.
27.
The Unit should undergo brake test as per instructions on pages 5, 6, and 7.
28.
Install Plastic Plug (22) into Spindle (1A).
Continued on Next Page
49
NOTE: Skip steps 29, 30 and 31 if unit does not have Adaptor Mounting (24).
29.
Grease and Install O-Ring (25) onto O-Ring groove of Adaptor Mount (24).
NOTE: Skip step 30, if Thrust Washer (30) is glued onto Adaptor Mount (24)
30.
Install Thrust Washer (30) onto Adaptor Mount (24).
31.
Install Adaptor Mount (24) onto Spindle (1A) using Bolts (26).
32.
The unit should now be leak and roll checked as per instructions on page 8, 9 & 10. The
motor can be reinstalled into the gearbox for the leak check to seal it off, and the unit
pressurized through a pipe plug hole on the cover.
This concludes the Main assembly.
50
Planetary Final Drive Service Manual
Assembly Drawing
51
Planetary Final Drive Repair Instructions
Parts List
Number
1A
Qty
1
Description
SPINDLE
1B
1
FACE SEAL
1C
2
BEARING CUP/ BEARING CONE
1E
1
BEARING NUT
1G
1
HOUSING
1H
10
STUDS
1U/14
2
PIPE PLUG
2
1
THRUST SPACER
3A
4
PLANET GEAR
3B
4
CYLINDRICAL ROLLER BEARING
3C
4
EXTERNAL RETAINING RING
3D
8
INTERNAL RETAINING RING
4/6
1
RING GEAR
5
2
O-RING
6
1
COVER SUB-ASSEMBLY
6A/12
1
COVER PLATE
7
1
INPUT SHAFT
8
1
CARRIER SUB-ASSEMBLY
8A
1
CARRIER
8B
12
THRUST WASHER
8C
54
BEARING NEEDLE
8D
3
PLANET SHAFT
8E
3
GROOVE PIN
8F
3
PLANET GEAR
9
1
COUPLING
10
1
THRUST WASHER
11
1
THRUST WASHER
12
1
SUN GEAR
15
4
DOWEL PIN
18
1
PISTON BRAKE SUB-ASSEMBLY
18A
1
PISTON BRAKE
18B
1
BRAKE THRUST PLATE
18C
7
STATOR
18D
6
ROTOR
Continued on Next Page
52
Number
Qty
18E
1
Description
INTERNAL RETAINING RING
18F
18G
18H
18I
18J
18R
1
1
1
1
1
*
O-RING
O-RING
BACKUP RING
BACKUP RING
SPACER
SPRING
22
21B
22
24
25
26
1
1
1
1
1
2
PLASTIC PLUG
EXTERNAL RETAINING RING
RETAINING RING
ADAPTOR MOUNT
O-RING
DRIVE SCREW
27/13
30
20
1
BOLT
THRUST WASHER
NOTE: * For Spring (18R) quantity, refer to the Brake Chart under Brake Test on page 6.
53
Planetary Final Drive Repair Instructions
Assembly Tools
T163056– ROLL CHECKING FIXTURE
54
T180149 – LEAK TEST ADAPTER
55
T184729 – LEAK TEST ADAPTER
56
T182969 – ROLL CHECK TOOL
57
T198122 – BRAKE ASSEMBLY CONCENTRICITY
58
T201476 – LEAK TEST ADAPTER PLATE
59
T176834 – ASSEMBLY PRESSING TOOL
60
T176703 – BEARING CONE PRESSING TOOL
61
T176285 – ASSEMBLY LOCKNUT WRENCH
62
T174699 – ASSEMBLY PRESSING TOOL
63
T219294 – SEAL PRESSING TOOL
64
T181663 – BRAKE ASSEMBLY CONCENTRICITY FIXTURE
65
T184035 – BRAKE ASSEMBLY CONCENTRICITY FIXTURE
66
T188489 – BRAKE ASSEMBLY CONCENTRICITY FIXTURE
67
T205279 – LEAK TEST ADAPTER PLATE
68
T179926 – ASSEMBLY PRESSING TOOL
69
Planetary Final Drive Repair Instructions
Contact Information
With more than 90 years of experience, Fairfield Manufacturing
Co. Inc. has become the largest U.S. non-captive producer of
gears, custom gear assemblies, planetary final drives and related
gear products. Fairfield Manufacturing Co. Inc., headquartered in
Lafayette, Indiana USA, is distinguished by our extensive design,
manufacturing and applications engineering capabilities.
Our 500,000 square foot plant is a modern, fully equipped
manufacturing facility that includes a full service heat treat
department.
Our philosophy of synchronous engineering is a partnership that
matches our best and brightest people with your people to evaluate
your unique requirements, and develop products and assemblies
that meet your needs.
For more information, contact Fairfield Manufacturing Co Inc. today.
Mailing Address
Fairfield Manufacturing Co. Inc.
U.S. 52 South / P.O. Box 7940
Lafayette IN 47903-7940
Shipping Address
2309 Concord Road
Lafayette, IN 47909
Fax
Main
Applications Engineering
Sales and Service
(765) 772-4001
(765) 772-4011
(765) 772-4010
E-mail
Applications Engineering
Sales
[email protected]
[email protected]
Website
www.oerlikon.com/fairfield
70
Oerlikon Fairfield
U.S. 52 South / P.O. Box 7940
Lafayette, IN 47903 USA
765-772-4000
www.oerlikon.com/fairfield
71